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Responding to Rising Memory and Component Costs: Streamlining Industrial Communication BOM and PCB Design with netX 90

Soaring Memory and Peripheral Component Costs: The Pressure on Traditional Multi-Chip Architectures

With recent price increases across memory components (SDRAM, NOR Flash, SRAM) and various industrial-grade electronic parts, equipment manufacturers developing servo drives, motion controllers, encoders, sensors, and remote I/O modules face mounting pressure from rising Bill of Materials (BOM) costs and supply chain volatility.
Conventional industrial communication hardware architectures typically rely on a multi-chip combination: Host Application MCU + Communication ASIC + External Memory + 2 Ethernet Physical Layer (PHY) Transceivers + Multi-Channel Power Regulators and Voltage Supervisors. As peripheral component prices climb, this architecture drives up total material costs and introduces sourcing risks (the "golden screw" component shortage problem), higher power dissipation, and severe PCB real estate constraints.
The most effective way to fundamentally lower hardware costs and design complexity is to reduce the on-board IC count. The netX 90 multi-protocol System-on-Chip (SoC) from German industrial communication specialist Hilscher integrates a dual-core processor, on-chip memory, power management, dual-port Ethernet PHYs, and hardware security features into an ultra-compact 10 × 10 mm (144-pin BGA) package, enabling engineers to significantly reduce peripheral components.

On-Chip 1.5 MB Flash & 640 KB SRAM: Flexible Configuration for Use Case A and Use Case C

Traditional communication processors often require external Flash for firmware storage and external RAM for network packet buffering. This adds component cost, and high-speed memory routing frequently introduces EMI/EMC compliance challenges.
The Hilscher netX 90 integrates ample internal memory directly on-chip:

Communication Side: 1024 KB (1 MB) Flash, 576 KB SRAM, and 128 KB Mask ROM dedicated strictly to industrial communication protocol stacks.
Application Side: An independent 512 KB Flash and 64 KB SRAM allocated for customer control programs.
Reliability: All internal memory blocks feature hardware ECC (Error-Correcting Code) protection.

In practical hardware development, Hilscher's firmware architecture allows manufacturers to flexibly manage memory costs based on target product tiers:

Lightweight Industrial Communication (Use Case A): For devices requiring standard real-time industrial Ethernet or fieldbus slave communication, the on-chip 1.5 MB Flash and 640 KB SRAM are completely self-sufficient. No external RAM or Flash is required, shielding the design from memory price volatility while achieving the smallest PCB footprint.
EU CRA Compliance & High-End Requirements (Use Case C): For devices targeting European export that must comply with the EU Cyber Resilience Act (CRA)—requiring fail-safe firmware update partitions and robust cryptographic storage—or systems running heavy IIoT applications (such as an embedded OPC UA Server or extended Webserver), the architecture expands via external SDRAM and SQI Flash.

Design Tip: Many equipment designers route a single PCB layout with footprints for external SDRAM and SQI Flash: for cost-sensitive standard markets, external memory footprints are left unpopulated (Do Not Populate / DNP) under Use Case A to minimize BOM cost; for EU-export or high-security markets, the memory is mounted to activate Use Case C. A single board design addresses both cost-competitive and high-compliance market tiers.

Dual-Core Cortex-M4 Architecture: Eliminating External Host MCUs

Regardless of choosing Use Case A or Use Case C, the most significant BOM reduction comes from eliminating the external host microcontroller (MCU).
The netX 90 features a dual-system architecture powered by two independent 100 MHz Arm Cortex-M4 processors (each delivering 125 DMIPS), each paired with a dedicated 100 MHz xPIC 32-bit RISC real-time co-processor:

Communication Core: Dedicated exclusively to running pre-certified Hilscher Loadable Firmware (LFW), handling demanding real-time industrial protocol processing and sub-microsecond synchronization without consuming application compute resources.
Application Core: Equipped with an integrated hardware Floating-Point Unit (FPU) and Memory Protection Unit (MPU), fully open for developers to run proprietary device control logic. Data exchanges with the communication core occur seamlessly via an internal 32-bit Dual-Port Memory (DPM).

This architecture allows small-to-midsize industrial devices (such as smart sensors, optical encoders, remote I/O blocks, and motor drives) to execute control firmware directly on the netX 90 application core—achieving a single-chip "industrial communication + equipment control" solution. For complex multi-axis motion controllers requiring high-end DSPs/MPUs, the netX 90 can also function as a high-performance companion chip via an external parallel DPM or high-speed SPI/SQI interface.

Integrated DC/DC Buck Converter, Voltage Supervision, and Dual-Port PHY

Beyond processors and memories, power distribution trees and network physical layers typically consume substantial PCB area and BOM budget. The netX 90 integrates these circuits on-chip:

Internal DC/DC Buck Converter & Single 3.3V Rail: An on-chip DC/DC switching regulator generates the core voltages from a single external 3.3V supply, eliminating external core buck regulators. Total SoC power dissipation remains under 1 W, eliminating the need for heatsinks.
Integrated POR, BOD, Clock Supervision & Thermal Diode: Integrated Power-on Reset (POR), Brown-out Detection (BOD), internal RC oscillator monitoring, and an on-die thermal diode remove the need for external voltage supervisor ICs while enabling real-time voltage and temperature tracking for predictive maintenance.
Integrated Dual-Port Fast Ethernet PHY: Industrial Ethernet topologies require dual network ports to support daisy-chain line wiring. The netX 90 directly integrates two 10/100 Mbps Fast Ethernet PHYs, a real-time hardware switch, and an IEEE 1588 precision hardware timestamping engine, saving two premium-priced industrial Ethernet PHY ICs.

Single Hardware Platform Supporting Multi-Protocol & Rich Industrial I/O

For motor control, sensing, and feedback applications, the netX 90 application side integrates rich industrial interfaces out-of-the-box:

2× EnDat 2.2 interfaces
2× BiSS / SSI master interfaces
2× Quadrature encoder inputs
8-channel IO-Link V1.1 master/device controller
Dedicated Motion PWM motor control unit
2× CAN 2.0B controllers
12-bit 2 Msps high-speed SAR ADC

This comprehensive peripheral set eliminates the need for companion CPLDs, FPGAs, or external interface bridge chips.
Furthermore, backed by Hilscher’s programmable xC flexible communication subsystem, equipment manufacturers only need to design, validate, and maintain one single hardware PCB. Protocol support can be switched entirely through loadable firmware:

Industrial Ethernet: PROFINET IO-Device (RT/IRT), EtherCAT Slave, EtherNet/IP Adapter (CIP Security), CC-Link IE Field Basic, Open Modbus/TCP, POWERLINK, Sercos, and VARAN.
Traditional Fieldbuses: PROFIBUS DP, CANopen, DeviceNet, CC-Link, and IO-Link Master.
IIoT Protocols: Embedded OPC UA Server and MQTT Client running concurrently alongside real-time control communications to push telemetry directly to edge or cloud platforms.

Protocol switching requires only a firmware update with zero hardware modifications. A single hardware platform meets worldwide line standards and regional customer requirements, drastically slashing R&D revision cycles and inventory management overhead (SKUs).

Hardware-Rooted Security: Ready for EU CRA and IEC 62443

The European Union Cyber Resilience Act (CRA) entered into force in late 2024 and becomes mandatory by late 2027, requiring connected industrial equipment to incorporate Security-by-Design principles throughout the product lifecycle.
The netX 90 integrates built-in hardware security designed specifically to meet IEC 62443 and CRA requirements from the silicon level up:

Multi-stage Secure Boot with cryptographic signature validation
Internal memory AHB firewall preventing unauthorized access between cores
FIPS 140-2 compliant hardware cryptographic accelerator supporting RSA-4096, ECC-512, AES-256, SHA-512, and TLS 1.2 secure communication

Combined with the Use Case C memory architecture, the netX 90 provides fail-safe secure firmware updates, cryptographic certificate management, and encrypted fieldbus communications, helping industrial manufacturers achieve regulatory CRA compliance ahead of time.

From Bare Silicon to Embedded Modules: Flexible Options Across Production Scales

In addition to discrete netX 90 SoC board-level design, Hilscher offers a complete portfolio of netX 90-based embedded module solutions for teams seeking faster time-to-market, simpler assembly without fine-pitch BGA soldering, or pre-certified RF/Ethernet designs:

netRAPID 90 (NRP H90): An ultra-compact solderable Chip Carrier package that mounts like a standard QFP component using conventional SMD pick-and-place lines, avoiding expensive high-density BGA fanout and multi-layer PCB stackups. The NRP H90\F8D8 variant integrates 8 MB RAM and 8 MB Flash, satisfying CRA security guidelines and IIoT connectivity out-of-the-box.
netRAPID 90IC (NRP H90IC\F8D8): A plug-in embedded communication module (measuring only 18 × 45 mm) secured via SMT connectors and retention screws. This "plug instead of solder" design includes 8 MB RAM and 8 MB Flash for CRA compliance, minimizing manufacturing risk and facilitating easy field replacement.
COMX 90CA-RE: A full-featured embedded module integrating dual-port RJ45 connectors, on-board magnetics, peripheral circuits, and 8 MB RAM / 8 MB Flash. It delivers a 65% power reduction compared to previous-generation COMX 51 modules while maintaining pin compatibility. Users can load their own protocol firmware on the COMX 90CA-RE or select the pre-loaded COMX 90CN series.
COMX 90CN Series: Eliminates on-board RJ45 jacks and routes physical signals out through a secondary SMT header, giving engineers full layout flexibility for custom enclosure connectors (e.g., M12 or angled RJ45).

Evaluation Boards & Local Support

Hilscher provides complete development kits for rapid prototyping:

NXHX 90-JTAG (general-purpose netX 90 development board) & NXHX 90-MC (motor control evaluation board)
NRPEB H90-RE & NSHIELD90-RE (evaluation boards for the netRAPID 90 series)
COMXEB (universal evaluation carrier board for the entire comX family)

For detailed specifications, evaluation board loan requests, and local commercial support in Taiwan, contact Hilscher’s official distributor, Alpha Pacific Technologies Co., Ltd. (亞德電子科技):

Phone: +886-2-2999-5456
Email: emma@alpha-pacific.com
Official LINE: @394gsmmc

Frequently Asked Questions (FAQ)

Q1: In light of memory price hikes, does netX 90 require external SDRAM or Flash?
A: It depends on application requirements. For standard, real-time industrial communication (Use Case A), netX 90 runs entirely from its internal 1.5 MB Flash and 640 KB SRAM without external memory. If your product requires EU CRA compliance, fail-safe firmware update partitions, or full-featured IIoT capabilities (Use Case C), external SDRAM and SQI Flash are required—or you can choose pre-integrated modules such as the NRP H90\F8D8, netRAPID 90IC, or COMX 90CA-RE.
Q2: Can the netX 90 operate stand-alone without an external host MCU?
A: Yes. The netX 90 incorporates two independent 100 MHz Arm Cortex-M4 cores. One core runs pre-certified industrial communication stacks, while the second core (equipped with hardware FPU and MPU) is fully accessible for user control logic. For small and medium-sized industrial equipment, this completely eliminates the external host MCU.
Q3: Which peripheral components can be eliminated from power and network circuits?
A: netX 90 integrates an internal DC/DC buck converter, Power-on Reset (POR), Brown-out Detection (BOD), clock supervision, and two 10/100M Ethernet PHYs. Operating from a single 3.3V supply with power consumption under 1 W, it eliminates external core regulators, voltage supervisor ICs, and two external industrial-grade Ethernet PHY transceivers.
Q4: Which industrial communication protocols are supported, and does switching protocols require a PCB redesign?
A: It supports PROFINET, EtherCAT, EtherNet/IP, CC-Link IE Field Basic, Modbus/TCP, POWERLINK, Sercos, PROFIBUS DP, CANopen, DeviceNet, as well as OPC UA and MQTT. Switching between protocols is handled entirely via loadable firmware, requiring zero hardware modifications or PCB respins.
Q5: What options exist if we prefer not to design a fine-pitch BGA board in-house?
A: You can select the surface-mount netRAPID 90 (QFP-style chip carrier), the plug-in netRAPID 90IC (no soldering required), or the integrated-jack COMX 90CA-RE / COMX 90CN modules. All options are supported by dedicated evaluation boards (such as the NRPEB H90-RE and COMXEB) for immediate bench evaluation.
Q6: Where can Taiwanese manufacturers source netX 90 silicon, modules, and evaluation kits?
A: Alpha Pacific Technologies (亞德電子科技) is the official distributor of Hilscher in Taiwan, supplying netX 90 ICs, netRAPID 90, netRAPID 90IC, COMX series modules, and development boards. Inquiries and sample requests can be directed to +886-2-2999-5456, emma@alpha-pacific.com, or official LINE ID @394gsmmc.